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A thermal overload device containing a polymer composite, which contains at least one polymer and a modified graphite oxide material, containing thermally exfoliated graphite oxide having a surface area of from about 300 m.sup.2/g to 2600 m.sup.2/g, and a method of making the same.
This is the final report which summarizes the research accomplishments under the project entitled 'Physics of Heat Pipe Rewetting' under NASA Grant No. NAG 9-525, Basic, during the period of April 1, 1991 to January 31, 1994. The objective of the research project was to investigate both analytically and experimentally the rewetting characteristics of the heated, grooved plate. The grooved plate is to simulate the inner surface of the vapor channel in monogroove heat pipes for space station design. In such designs, the inner surface of the vapor channel is threaded with monogrooves. When the heat pipe is thermally overloaded, dryout of the monogroove surface occurs. Such a dryout surface should be promptly rewetted to prevent the failure of the heat pipe operation in the thermal radiator of the space station.
Missions of Gemini VI through XI covering rendezvous, docking, thermal overloading, translation maneuver, etc
Liquid distributed more evenly in evaporator section. Improved heat pipe contains an artery and wick rolled from stainless-steel screen of 180 mesh (openings about 80 micrometers). Screen material helps to prevent dryout in evaporator section by conducting liquid through hotspots and to vaporchannel wall. Insert reduces incidence of dryout at hotspots or during intervals of general thermal overload.
Foil gas bearings under development for rotorcraft-sized, hot core engine applications have been susceptible to damage from the slow acceleration and rates typically encountered during the pre-ignition stage in conventional engines. Recent laboratory failures have been assumed to be directly linked to operating foil bearings below their lift-off speed while following conventional startup procedures for the engines. In each instance, the continuous sliding contact between the foils and shaft was believed to thermally overload the bearing and cause the engines to fail. These failures highlight the need to characterize required acceleration rates and minimum operating speeds for these applications. In this report, startup experiments were conducted with a large, rotorcraft engine sized foil bearing under moderate load and acceleration rates to identify the proper start procedures needed to avoid bearing failure. The results showed that a bearing under a 39.4 kPa static load can withstand a modest acceleration rate of 500 rpm/s and excessive loitering below the bearing lift-off speed provided an adequate solid lubricant is present.
Shrink-fit stainless-steel insert in aluminum equipment housing allows electrical connectors to be replaced by soldering, without degrading hermeticity of housing or connector. Welding could destroy electrostatic-sensitive components and harm housing and internal cables. Steel insert avoids problems because connector soldered directly to it rather than welded to housing. Seals between flange and housing, and between connector and flange resistant to leaks, even after mechanical overloading and thermal shocking.
Double-wall heat-exchanger tube protects from overloads by changing thermal resistance automatically. When temperature at any location on tube increases above prescribed limit, thermal resistance through walls of tube increases at location. Prevents local excess heat load from overheating tube or boosting internal pressure and weakening tube, shortening life expectancy, or destroying it. When heat load falls to normal level, tube automatically lowers thermal resistance and resumes heat exhange at rated capacity.
Successfully executing proximity operations in space, such as docking or in-orbit servicing, requires sophisticated spacecraft design that accounts for induced environments. As a chaser vehicle’s attitude control thrusters fire, they create rarefied plumes that can impact the target vehicle, with the potential to overload components, exceed thermal limits, and spin the target vehicle out of control. High-fidelity simulations of the thruster plume impingement environment require the direct simulation Monte Carlo (DSMC) method, but DSMC is too computationally expensive to simulate proximity operations that involve thousands of thruster firings. For this analysis to be tractable, engineering models of the plume flowfield and impingement events are used to simulate these trajectories [1]. Currently, on-orbit plume impingement environments are modeled through an inefficient open-loop analysis cycle where the vehicle’s flight controller and plume impingement teams iterate on the trajectories until they pass the target vehicle’s plume requirements. As complex on-orbit missions evolve and become more frequent, lengthy design cycles will become operational bottlenecks. To address this gap, this work develops an advanced plume impingement module capable of operating at real-time scale that can be integrated with existing mission planning tools and onboard flight systems. The plume module leverages state-of-the-art plume simulation techniques [2] to deliver fast, physics-based impingement predictions in a software architecture that can be tailored to diverse proximity operations scenarios. A prototype of this plume impingement module is built to demonstrate the feasibility of real-time performance. This prototype completes plume impingement calculations in microseconds per target geometry mesh point. The software serves as a foundational capability for plume-aware trajectory design, operational risk assessment, and future autonomous decision-making systems.
The physical damage incurred by the solid rocket boosters during reentry on the initial space shuttle flight raised the question of whether the hardware, as designed, would yield the low cost per flight desired. The damage was quantified, the cause determined and specific design changes recommended which would preclude recurrence. Flight data, postflight analyses, and laboratory hardware examinations were used. The resultant findings pointed to two principal causes: failure of the aft skirt thermal curtain at the onset of reentry aerodynamic heating, and overloading of the aft shirt stiffening rings during water impact. Design changes were recommended on both the thermal curtain and the aft skirt structural members to prevent similar damage on future missions.
Addition of metallic outer layer deposited by standard plating method, having high thermal conductivity, substantially reduces thermal stress in high-temperature/high-strength materials, preventing structural overloads.
Electronic load circuit for displaying current/voltage characteristic curves of power sources uses low-cost low-power CMOS operational amplifiers to control load current flowing through power MOSFET Q2 and main load transistor Q3. Thermal cutoff device turns off transistor Q3 in case of overload. To maximize battery life, battery is connected via "push-to-read" momentary-contact pushbutton switch.
A strain-gage-balance (SGB) force-measurement system is described which was designed to meet light-load requirements for an airfoil model tested in the NASA Langley low-turbulence pressure tunnel (LTPT). This system was developed to obtain direct force data needed to verify calculated pressure/force correlations used in previous aerodynamic tests. The three-component force-measurement system was designed so that the SGBs would simultaneously support and measure the following loads: weight of the airfoil (approximately 3.0 lbf); 8.0 lbf of lift; 0.5 lbf of drag; and 16.0 in. lbf of pitching moment. In addition to these design loads, the system was required to withstand 100-percent overload on all three components. The system comprises an airfoil, two SGBs, a thermal flexure, and a mounting plate. The installation of the system in the LTPT is also discussed.
Two primary problems resulted from plasma interactions; one of concern to operations in geosynchronous orbit (GEO), the other in low orbits (LEO). The two problems are not the same. Spacecraft charging has become widely recognized as a problem, particularly for communications satellites operating in GEO. The very thin thermal plasmas at GEO are insufficient to bleed off voltage buildups due to higher energy charged particle radiation collected on outer surfaces. Resulting differential charging/discharging causes electrical transients, spurious command signals and possible direct overload damage. An extensive NASA/Air Force program has been underway for several years to address this problem. At lower altitudes, the denser plasmas of the plasmasphere/ionosphere provide sufficient thermal current to limit such charging to a few volts or less. Unfortunately, these thermal plasma currents which solve the GEO spacecraft charging problem can become large enough to cause just the opposite problem in LEO.
In order to accommodate the growing thermal management needs of future space platforms, several two-phase active thermal control systems (ATCSs) have evolved and were included in the designs of space stations. Compared to the pumped single-phase liquid loops used in the conventional Space Transportation System and Spacelab, ATCSs offer significant benefits that may be realized by adopting a two-phase fluid-loop system. Alternately, dynamic power systems (DPSs), based on the Rankine cycle, seem inevitably to be required to supply the electrical power requirements of expanding space activities. Boiling heat transfer is one of the key technologies for both ATCSs and DPSs. Nucleate boiling near critical heat flux (CHF) can transport very large thermal loads with much smaller device size and much lower pumping power. However, boiling performance deteriorates in a reduced gravity environment and operation in the CHF regime is precarious because any slight overload will cause the heat transfer to suddenly move to the film boiling regime, which in turn, will result in burnout of the heat transfer surfaces. New materials, such as micro-configured metal-graphite composites, can provide a solution for boiling enhancement. It has been shown experimentally that this type of material manifests outstanding boiling heat transfer performance and their CHF is also extended to higher values. Due to the high thermal conductivity of graphite fiber (up to 1,200 W/m-K in the fiber direction), the composite surfaces are non-isothermal during the boiling process. The composite surfaces are believed to have a much wider safe operating region (a more uniform boiling curve in the CHF regime) because non-isothermal surfaces have been found to be less sensitive to variations of wall superheat in the CHF regime. The thermocapillary forces formed by the temperature difference between the fiber tips and the metal matrix play a more important role than the buoyancy in the bubble detachment, for the bubble detachment manifests itself by a necking process which should not be weakened by reduced gravity. In addition, the composite surfaces introduce no extra pressure drop, no fouling and do not impose significant primary or maintenance costs. All of these suggest that this type of composite is an ideal material for the challenge of accounting for both reliability and economy of the relevant components applied in the ATCSs, the DPSs and other devices in future space missions. The aim of the proposed work is to experimentally investigate high nucleate pool boiling performance on a micro-configured metal-graphite composite surface and to determine the mechanisms of the nucleate boiling heat transfer both experimentally and theoretically. Freon-113 and water will be used as the test liquids to investigate wettability effects on boiling characteristics. The Cu-Gr and Al-Gr composites with various volume fractions of graphite fibers will be tested to obtain the heat transfer characteristic data in the nucleate boiling region and in the CHF regime. In the experiments, the bubble emission and coalescence processes will be recorded by a video camera with a magnifying borescope probe immersed in the working fluid. The temperature profile in the thermal boundary layer on the composite surfaces will be measured by a group of micro thermocouples consisting of four ultra fine micro thermocouples. This instrument was developed and successfully used to measure the temperature profile of evaporating liquid thin layers by the proposers in a study performed at the NASA/Lewis Research Center. A two tier model to explain the nucleate boiling process and the performance enhancement on the composite surfaces has been suggested by the authors. According to the model, the thicknesses of the microlayer and the macrolayer underneath the bubbles and mushrooms, can be estimated by the geometry of the composite surface. The experimental results will be compared to the predictions from the model, and in turn, to revise and improve it.
An improved foil thrust bearing is described that eliminates or reduces the need for forced cooling of the bearing foils while at the same time improves the load capacity of the bearing, enhances damping, provides overload tolerance, and eliminates the high speed load capacity drop-off that plagues the current state of the art. The performance improvement demonstrated by the chevron foil thrust bearing stems from a novel trailing edge shape that splays the hot lubricant in the thin film radially, thus preventing hot lubricant carry-over into the ensuing bearing sector. Additionally, the chevron shaped trailing edge induces vortical mixing of the hot lubricant with the gas that is naturally resident within the inter-pad region of a foil thrust bearing. The elimination of hot gas carry-over in combination with the enhanced mixing has enabled a completely passive thermally managed foil bearing design. Laboratory testing at NASA has confirmed the original analysis and reduced this concept to practice.
The design, development, and operation of long duration spaceflight hardware has become an evolutionary process in which meticulous attention to details and lessons learned from previous experiences play a critical role. Invaluable to this process is the ability to retrieve and examine spaceflight hardware that has experienced a premature failure. While these situations are rare and unfortunate, the failure investigation and recovery from the event serve a valuable purpose in advancing future space mechanism development. Such a scenario began on July 31, 2010 with the premature failure of an ammonia pump on the external active thermal control system of the International Space Station. The ground-based inspections of the returned pump and ensuing failure investigation revealed five potential bearing forces that were un-accounted for in the design phase and qualification testing of the pump. These forces could combine in a number of random orientations to overload the pump bearings leading to solid-surface contact, wear, and premature failure. The recovery plan identified one of these five forces as being related to the square of the operating speed of the pump and this fact was used to recover design life through a change in flight rules for the operation of the pump module. Through the course of the failure investigation, recovery, and follow-on assessment of pump wear life, design guidance has been developed to improve the life of future mechanically pumped thermal control systems for both human and robotic exploration missions.
The findings of electrical short circuit and current overload tests performed on commercial aircraft wiring are presented. A series of bench-scale tests were conducted to evaluate circuit breaker response to overcurrent and to determine if the wire showed any visible signs of thermal degradation due to overcurrent. Three types of wire used in commercial aircraft were evaluated: MIL-W-22759/34 (150 C rated), MIL-W-81381/12 (200 C rated), and BMS 1360 (260 C rated). A second series of tests evaluated circuit breaker response to short circuits and ticking faults. These tests were also meant to determine if the three test wires behaved differently under these conditions and if a short circuit or ticking fault could start a fire. It is concluded that circuit breakers provided reliable overcurrent protection. Circuit breakers may not protect wire from ticking faults but can protect wire from direct shorts. These tests indicated that the appearance of a wire subjected to a current that totally degrades the insulation looks identical to a wire subjected to a fire; however the 'fire exposed' conductor was more brittle than the conductor degraded by overcurrent. Preliminary testing indicates that direct short circuits are not likely to start a fire. Preliminary testing indicated that direct short circuits do not erode insulation and conductor to the extent that ticking faults did. Circuit breakers may not safeguard against the ignition of flammable materials by ticking faults. The flammability of materials near ticking faults is far more important than the rating of the wire insulation material.
Two general types of remote power controller (RPC) that combine the functions of a circuit breaker and a switch were developed for use in direct-current (dc) aerospace systems. Power-switching devices used in these designs are the relatively new gate-turnoff thyristor (GTO) and poweer metal-oxide-semiconductor field-effect transistors (MOSFET). The various RPC's can switch dc voltages to 1200 V and currents to 100 A. Seven different units were constructed and subjected to comprehensive laboratory and thermal vacuum testing. Two of these were dual units that switch both positive and negative voltages simultaneously. The RPC's using MOSFET's have slow turnon and turnoff times to limit voltage spiking from high di/dt. The GTO's have much faster transition times. All RPC's have programmable overload tripout and microsecond tripout for large overloads. The basic circuits developed can be used to build switchgear limited only by the ratings of the switching device used.